Cross-Section Bead Image Prediction in Laser Keyhole Welding of AISI 1020 Steel Using Deep Learning Architectures

A deep learning model was applied for predicting a cross-sectional bead image from laser welding process parameters. The proposed model consists of two successive generators. The first generator produces a weld bead segmentation map from laser intensity and interaction time, which is subsequently translated into an optical microscopic (OM) image by the second generator. Both generators exhibit an encoder & x2013;decoder structure based on a convolutional neural network (CNN). In the second generator, a conditional generative adversarial network (cGAN) was additionally employed with multiscale discriminators and residual blocks, considering the size of the OM image. For a training dataset, laser welding experiments with AISI 1020 steel were conducted on a large process window using a 2 KW fiber laser, and a total of 39 process conditions were used for the training. High-resolution OM images were successfully generated, and the predicted bead shapes were reasonably accurate (R-Squared: 89.0 & x0025; for penetration depth, 93.6 & x0025; for weld bead area)

In-Situ Defect Detection in Laser Powder Bed Fusion by Using Thermography and Optical Tomography—Comparison to Computed Tomography

Among additive manufacturing (AM) technologies, the laser powder bed fusion (L-PBF) is one of the most important technologies to produce metallic components. The layer-wise build-up of components and the complex process conditions increase the probability of the occurrence of defects. However, due to the iterative nature of its manufacturing process and in contrast to conventional manufacturing technologies such as casting, L-PBF offers unique opportunities for in-situ monitoring. In this study, two cameras were successfully tested simultaneously as a machine manufacturer independent process monitoring setup: a high-frequency infrared camera and a camera for long time exposure, working in the visible and infrared spectrum and equipped with a near infrared filter. An AISI 316L stainless steel specimen with integrated artificial defects has been monitored during the build. The acquired camera data was compared to data obtained by computed tomography. A promising and easy to use examination method for data analysis was developed and correlations between measured signals and defects were identified. Moreover, sources of possible data misinterpretation were specified. Lastly, attempts for automatic data analysis by data integration are presented

Micro-manufacturing : research, technology outcomes and development issues

Besides continuing effort in developing MEMS-based manufacturing techniques, latest effort in Micro-manufacturing is also in Non-MEMS-based manufacturing. Research and technological development (RTD) in this field is encouraged by the increased demand on micro-components as well as promised development in the scaling down of the traditional macro-manufacturing processes for micro-length-scale manufacturing. This paper highlights some EU funded research activities in micro/nano-manufacturing, and gives examples of the latest development in micro-manufacturing methods/techniques, process chains, hybrid-processes, manufacturing equipment and supporting technologies/device, etc., which is followed by a summary of the achievements of the EU MASMICRO project. Finally, concluding remarks are given, which raise several issues concerning further development in micro-manufacturing

MIG gas shielding : Economic savings without detriment to quality

Over the years a number of claims have been made related to potential savings of the shielding gas used in the MIG process. A number of work streams have been set up to consider such areas from a technical and economic standpoint. The use of small helium additions has particular benefits and despite an increase in unit cost, the overriding benefits are achieved in reduced manhour cost. A similar situation has been established when using a high frequency process to switch shielding gases during welding. The outcome from this was very similar to that already described. Overlaid on these has been the increasing use of a technique that visualises actual gas flow during welding by the use of laser backlighting. Some preliminary work in this area is described particularly related to the effect of drafts on the gas distribution. A recent development on the market place is a piece of equipment, which regulates the gas flow automatically and synchronously with the welding current. Gas savings in the region of 50-60% have been obtained. Data has been produced to illustrate these benefits. The potential benefit of developing a computational fluid dynamic model of the gas flow is also described, and early development stages of the model shown. However, there will always exist the very basic management need to minimise leaks from the gas delivery systems

The influence of position in overlap joints of Mg and Al alloys on microstructure and hardness of laser welds

Structure and properties of laser beam welding zone of dissimilar materials, AZ31 magnesium alloy and A5754 Aluminum alloy, are investigated. The microstructure and quality of the Mg/Al weld were studied by metallography, microhardness and optical microscopy. Differences in physical and mechanical properties of both materials, magnesium and aluminum, affect weldability and resistance of this combination, and lead to the formation of intermetallic compounds in the welded metal

Using Taguchi method to optimize welding pool of dissimilar laser welded components

In the present work CO2 continuous laser welding process was successfully applied and optimized for joining a dissimilar AISI 316 stainless steel and AISI 1009 low carbon steel plates. Laser power, welding speed, and defocusing distance combinations were carefully selected with the objective of producing welded joint with complete penetration, minimum fusion zone size and acceptable welding profile. Fusion zone area and shape of dissimilar austenitic stainless steel with ferritic low carbon steel were evaluated as a function of the selected laser welding parameters. Taguchi approach was used as statistical design of experiment (DOE) technique for optimizing the selected welding parameters in terms of minimizing the fusion zone. Mathematical models were developed to describe the influence of the selected parameters on the fusion zone area and shape, to predict its value within the limits of the variables being studied. The result indicates that the developed models can predict the responses satisfactorily

A Review of Welding in Space and Related Technologies

Deployment of welding and additive manufacturing (AM) technologies in the space environment has the potential to revolutionize how orbiting platforms are designed, manufactured, and assembled. These technologies offer the option for repair of sustained damage to habitat structures on space missions, as astronauts would be able to manufacture new parts (using welding-derived AM processes suitable for use in the external space environment) and weld cracks. An added benefit is that required repairs can be achieved more economically, as new parts need not be shipped from Earth. With further maturation of in-space welding capabilities, astronauts could operate under given standards and weld damaged structures rather than rely on cargo resupply. This Technical Memorandum (TM) begins by reviewing the available literature relevant to welding in space, focusing on solidification, heat and mass transfer, and fluid flows in microgravity. This survey considers research on the effects of welding in microgravity on a material system. The various in-space welding devices that have been previously designed and tested are examined to determine their capabilities and shortcomings, with a focus on the results of their individual welding experiments. Safety measures are discussed to protect the orbiting International Space Station (ISS) and crew during welding operations. Finally, the state of the art is examined by focusing on current approaches to AM and on-orbit welding that are being developed by several companies in conjunction with NASA

Nonterrestrial utilization of materials: Automated space manufacturing facility

Four areas related to the nonterrestrial use of materials are included: (1) material resources needed for feedstock in an orbital manufacturing facility, (2) required initial components of a nonterrestrial manufacturing facility, (3) growth and productive capability of such a facility, and (4) automation and robotics requirements of the facility